Wall construction



a. 'D RATLI-F F JR, 3,495,417

WALL conswnu'c'nou Feb. 17, 1970 4-Sheets-Sheet 1 Filed June 14, 1968 WMQN QM \N QN [MENTOR GEORGE 0. RATL/FF JR- N Horny Feb. 17, 1970 G. ing,,R 3,495,411

WALL cofl's'raubnpfi I K4 sheets-sheet 2 Filed June 14. 1968 30 EXPOSURETIME IN MINUTES I i N A l E m. H M T m M Q E 0 5 0 m m m m m 7 "IVE/ Tm650E650. RAT IFF JR. r

AHomo'y Feb. 1 7, 1970 e. D,- ATLIFF, JR 3,495,417

WALL cousfaucnon I I Fil'ed June 14, 1968 4 {ShtS-Sheet 3 .9 {PANEL 9l/WEWTOR GEORGE mm. IFF JR.

Attorney Feb. 17 1970 e. D. RATLIFF, JR 3,495,417

WALL CONSTRUCTION Filed June 14, 1968 '4 Sheets-S heet 4 INVENTOR650E650. RATL/FF .10. y

Attorney United States Patent U.S. jCl. 52-168 14 Claims ABSTRACT OF THEDISCLOSURE This invention relates to non-bearing walls or partitionsand, more particularly, to improved sound-proof, nonibearing walls orpartitions which successfully pass ASTM Standard E1l9-61 fire tests forone and two hours. In a building structure, a partition wall is providedcomprising a plurality of aligned modular panels. Each panel includes apair of wallboards disposed in spaced substantially parallel relationand channel-shaped spacer members interposed between the wall-boardsalong two opposite edges thereof. The wallboards and the spacer membersdefine an air space. Each spacer member includes a web bridging the airspace between the wallboards and a pair of substantially parallelflanges extending toward, but terminating short of, the opposite edgesof the wallboards. Fasteners penetrate the wallboards and the flanges ofthe spacer members. Each fastener has an end extending inwardly of thespacer members. Contiguous edges of the wallboards of the aligned panelsare positioned in abutting relationship and form joints between thealigned wallboards. The spacer members contiguous to said joints form acavity. The flanges of the spacer members are spaced apart and defininga gap on opposite sides of the cavity. A fire-resistant spline member isdisposed in and bridges the cavity. The opposite lateral sides of thespline member are seated in the gaps on the opposite sides of the cavityand overlays the joints between the abutting edges of the wallboards.Fire-resistant clearance members are secured to the opposite sides ofthe spline memher, and the clearance members are of less lateral extentthat the spline member, thereby clearing the ends of the fasteners.

BACKGROUND OF THE INVENTION In order to satisfactorily pass the ASTMStandard E119-61 fire tests for a non-bearing wall and partition,certain conditions must be met. First, the wall or partition mustwithstand the fire endurance-test (without passage of flame or gases hotenough to ignite cotton waste) for a period equal to that for whichclassification is desired. After the fire test the specimen is thensubjected to the impact, erosion and cooling effects of a hose streamdirected first at the middle and then at all parts of the exposed face,changes in direction being made slowly. Thirdly, transmission of heatthrough the wall or partition during the fire endurance test shall nothave been such as to raise the temperature on its unexposed surface morethan 250 F. (139 C.) above its initial temperature.

OBJECTS OF THE INVENTION It is the general object of the presentinvention to avoid and overcome the foregoing and other difliculties ofand objections to prior art practices by the provision of prefabricatedpanel:

(a) Which has an increased fire rating; and

(b) Which is an improved sound barrier.

BRIEF SUMMARY OF THE INVENTION- The aforesaid objects of this invention,and other ob jects which will become apparent as the descriptionproceeds, are achieved by providing a partition Wall com prising aplurality of aligned modular panels. Each panel includes a pair ofwallboards disposed in spaced substantially parallel relation andchannel-shaped spacer members interposed between the wal=boards alongtwo opposite edges thereof. The wallboards and the spacer members definean air space. Each spacer member includes a web bridging the air spacebetween the wallboards and a pair of substantially parallel flangesextending toward, but terminating short of, the opposite edges of thewall-boards. Fasteners penetrate the wallboards and the flanges of thespacer members. Each fastener has an end extending inwardly of thespacer members. Contiguous edges of the wallboards of the aligned panelsare positioned in abutting relationship and form joints between thealigned wallboards. The spacer members contiguous to said joints form acavity. The flanges of the spacer members are spaced apart and defininga gap on opposite sides of the cavity. A fireresistant spline member isdisposed in and bridges the cavity. The opposite lateral sides of thespline member are seated in the gaps on the opposite sides of the cavityand overlay the joints between the abutting edges of the wallboards.Fire-resistant clearance members are secured to the opposite sides ofthe spline member, and the clearance members are of less lateral extentthan the spline member, thereby clearing the ends of the fasteners.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS For a betterunderstanding of this invention reference should be had to theaccompanying drawings, wherein like numerals of reference indicatesimilar parts throughout the several views and wherein:

FIGURE 1 is an exploded perspective view of a single panel wall of thisinvention capable of a one hour fire test and showing the novel heatsink, panel joint spline and panel end spline;

FIGURE 2 is a horizontal sectional view of the panel joint spline takenalong the line II-H of FIGURE 1 in the direction of the arrows;

FIGURE 3 is a horizontal sectional view of the panel end spline takenalong the line IIIIII of FIGURE 1 in the direction of the arrows;

FIGURE 4 is a horizontal sectional view of the heat sink taken along theline lV-IV of FIGURE 1 in the direction of the arrows;

FIGURE 5 is a graph of the exposure time and the highest temperaturemeasured on the unexposed side of two test panel specimens;

FIGURE 6 is a view similar to FIGURE 4 of an alternative embodiment of aheat sink;

FIGURE 7 is a view similar to FIGURES 4, 6 of a further alternative viewof the heat sink;

FIGURE 8 is a fragmentary plan view of a double panel Wall capable of atwo hour fire test;

FIGURE 9 is a view similar to FIGURE 8 of another alternative embodimentof a double panel;

FIGURE 10 is a schematic view of an automatic screwdriver provided witha depth insertion adapter for setting the fasteners of FIGURE 9;

FIGURE 11 is a fragmentary plan view of a toggletype fastener; and

FIGURE 12 is a view similar to FIGURE 11 of an anchor-type fastener.

Although the principles of this invention are broadly applicable towalls and partitions, this invention is particularly adapted for use inconjunction with a non-bearing, fire-proof wall or partition and henceit has been so illustrated and will be so described.

DETAILED DESCRIPTION With specific reference to the form of thisinvention illustrated in the drawings, and referring particularly toFIGURE 1, a fire-resistant, non-bearing panel wall is indicatedgenerally by the reference numeral 10.

This panel (FIGURE 1) has a top sill 12 and a bottom sill 14 (suitablywood or the like) disposed in spaced relation to the top sill 12. Endsupport members, such as the ZS-gauge galvanized steel channels or studs16, 17 or the like are connected to the top sill 12 and bottom sill 14by having the ends of such studs 16, 17 positioned in slots 18 in thetop sill 12 and bottom sill 1-4 and integrate the top sill 12 with thebottom sill 14. A first wall board member 20, such as about a /2-inchthick gypsum wallboard or the like of the type X produced by the US.Gypsum Company, Chicago, Illinois, is connected to one side (in thiscase the back side) of the top sill 12, bottom sill 14 and end supportmembers 16, 17 by fasteners 21, such as nails, screws or the like. Asecond wallboard member 22, similar to the first wallboard member 20, isconnected by other similar fasteners 21 to the other side of the topsill 12, bottom sill 14 and the end support members 16, 17 and defineswith the first wallboard member .20 an air space 24.

As shown in FIGURES 1 and 2, a spline member, suitably a panel jointspline 26, is positioned in one of the end support members 16, 17 (inthis case end support member 16) to provide a physical fire barrierthrough a wall joint 28 of adjacent wall panels 10, 10a (FIGURE 2).Referring to FIGURE 2, the panel joint spline 26 has a barrier member 30to seal the wall joint 28 which barrier member 30 is disposed adjacentclearance members 32 (to block a flame path through the wall joint 28)and is disposed adjacent end support members 16, 17a to provideclearance for the already-inserted fasteners 21. The barrier member 30and clearance members 32 are, for example, /2 -inch fire-rated gypsumwallboard and are integrated by fasteners 21a, such as 1% longannular-ringed drywall nails on 16-inch centers on both sides.

As shown in FIGURES 1, 3, the panel end spline 26a has a barrier member30 and one clearance member 32 for use against end walls (not shown).All joints are sealed on the outside surface by tape 31.

Referring now to FIGURES 1, 4, an internal support member 34substantially identical to the end support members 16, 17 is disposedbetween the end support members 16, 17 and the top sill 12 and bottomsill 14. A heat sink member 36, suit-ably /z-inch fire-rated gypsumwallboard, is provided in the internal support member 34 and securedthereto by fasteners 21a, such as l fit-inch long annular-ringed drywallnails at the center, top and bottom of the internal support member 34(FIGURE 4). The fasteners 21, suitably 1-inch long self-drilling,self-tapping drywall screws (type G supplied by US. Gypsum Company,Chicago, Illinois) on l2-inch centers of the edges of the internalsupport member 34 connect both the first wallboard member and the secondwallboard member 22 to the internal support member 34. The fasteners 21extend through one of the first wallboard member 20 and the secondwallboard member 22 and the internal support member 34 and into the heatsink member 36, thereby preventing heating of the fastener 21 above thefailure temperature of the fire test (i.e. 250 F. above starting ambienttemperature).

The heat sink member 36 contains a material, such as water, having alatent heat of vaporization and the material is operable duringvaporization thereof to prevent a temperature rise in the fastener 21 asshown by the test results of the test specimens illustrated in FIGURE 5.The fire-rated gypsum wallboard in the heat sink member 36 is amaterial, such as water which is chemically bonded to CaSO approximatelyas represented by the formula CaSO .6I-I O. Alternatively, concrete,such as vermiculite type, containing a material, such as water which ischemically and mechanically bonded to the cement may be used.

Alternatively, as shown in FIGURE 6, a hollow heat sink member 36containing a material, such as water which is employed. The heat sinkmember 36 is formed of a self-sealing material, such as foam rubber orthe like.

As shown in FIGURE 7, the above-described heat sink members 36 (FIGURE4) and 36 (FIGURE 6) may be affixed by an adhesive fastener 21b (such asSynco 935D adhesive prepared by Synco Resins Division, Ashland OilCompany, Louisville, Kentucky) to the wallboard members 20, 22 and toeach other.

ALTERNATIVE EMBODIMENTS It will be understood by those skilled in theart that alternatively as shown in FIGURE 8, a wall 40 may have a firstpanel 42 and a second panel 44, each having a top sill 12 and a bottomsill 14 disposed in spaced relation to the top sill 12 End supportmembers (not shown) are connected to (as shown in FIGURE 1) the top sill12 and bottom sill 14 Similarly a first wallboard member 20 and a secondwallboard member 22 are connected respectively to opposite sides of thetop sill 12 bottom sill 14 and end support members (not shown) byfasteners (not shown). One of the first wallboard member 20 and thesecond wallboard member 22 of the first panel 42 (in this case the firstwallboard member 20 has a first joint 46. In addition, one of the firstwallboard member 20 and the second wallboard 22 of the second panel 44(in this case the first wallboard member 20 has a second joint 48. Afirst internal support member 34 suitably face-to-face support members34, are disposed adjacent the first joint 46 and second joint 48 in therespective air spaces 24 The first joint 46 and the second joint 48 aredisplaced from each other a distance D (FIGURE 8) to provide a tortuousfire and sound path through the first panel 42 and the second panel 44.

Also, as shown in FIGURE 8, the other of the first wallboard member 20and the second wallboard member 22 of the first panel 42 (i.e. thesecond wallboard member 22 has a third joint 50 in alignment with afirst joint 46a. 1

Similarly the other of the first wallboard member 20 and the secondwallboard member 22 of the second panel 44, namely the second wallboardmember 22 has a fourth joint 52 in alignment with a'second joint 48a. An'air space 53 is provided between the first panel 42 and the secondpanel 44.

As shown in the double panel wall 40 of FIGURE 9, a filler wallboardmember 54, similar to the wallboard members 20 22 is connected to thesecond wallboard member 22 of the first panel 42 by a fastener 56 havinga head 58 protruding a' predetermined distance d from the fillerwallboard member 54. This fastener 56, suitably a type G Bug'leheaddrywall screw provided by US. Gypsum Company, Chicago, Illinois,.isoperable to bulge the adjacent side walls at 60, 62 of the fillerwallboard member 54 and the secondwallboard member 22 of the first panel42 to space the filler wallboard member 54 from such second wallboardmember 22 and to define a second air space64 therebetween. The secondpanel 44 has its first wallboard member20 positioned against theprotruding heads 58 of the fasteners 56 to define therewith a third airspace 66.

In order to set the fasteners 56 of FIGURE-9, an autom'atics'crewdriver68 (FIGURE 10), suitably a model 172 power screwdriver produced by theSkil Power Tool Company, Chicago, Illinois, is provided with'la switchshut-off adapter'70, Which adapter'70 engages the outer surface 'of thefiller wallboard member-54 and moves backwardly with respect to thehousing 71 of the screwdriver 68 a distance di to close a switch (notshown) thus shutting off the screwdriver 68, thereby providing theprotruding head 58 and thus preventing stripping of the holes in thesecond wallboard member 20 of the firstpanel 42 and in the fillerwallboard member 54.

Referring to FIGURE 9, adhesive beads 76, (such as Perf-a-Tape jointcompound or USG Laminating Adhesive trade names of U.S. Gypsum Company,Chicago, Illinois) are employed to secure the filler wallboard 54 to thefirst wallboard member 20 of the second panel 44 in spaced relationtherewith.

Alternatively, as shown in FIGURE 11, a toggle-type fastener 56 having atoggle sleeve 72 and a bolt 74 is employed. In FIGURE 12 an expansibleanchor-type fastener 56 having an expansion sleeve 72 (provided withexpansion slot 75) and a bolt 74 is used.

SUMMARY OF THE ACHIEVEMENT OF THE OBJECTS OF THE INVENTION It will berecognized by those skilled in the art that the objects of thisinvention have been achieved by providing a one-hour fire test panel(FIGURES 1-7) and the two-hour test double-panelled walls 40 (FIG- URE8) and 40 (FIGURE 9) which walls 40, 40 provide improved fire and soundresistance.

While in accordance with the patent statutes preferred and alternativeembodiments of this invention have been illustrated and described indetail, it is to be particularly understood that the invention is notlimited thereto or thereby.

I claim:

1. In a building structure:

(a) a partition wall comprising a plurality of aligned modular panels,

(1) each panel including a pair of wallboards disposed in spacedsubstantially parallel relation and channel-shaped spacer membersinterposed between said wallboards along two opposite edges thereof,

(b) said wallboards and said spacer members defining an air space,

(c) each spacer member including a web bridging said said air spacebetween said wallboards and a pair of substantially parallel flangesextending toward, but terminating short of, said opposite edges of saidwallboards,

(d) fasteners penetrating said wallboards and said flanges of saidspacer members,

(1) each fastener having an end extending inwardly of said spacermembers,

(e) contiguous edges of said wallboards of said aligned panels beingpositioned in abutting relationship and forming joints between saidaligned wallboards,

(f) said spacer members contiguous to said joints forming a cavity,

(g) said flanges of said spacer members being spaced apart and defininga gap on opposite sides of said cavity,

(h) a fire-ressitant spline member disposed in bridging said cavity,

(i) the opposite lateral sides of said spline member being seated insaid gaps on said opposite sides of said cavity and overlying saidjoints between said abutting edges of said wallboards,

(j) fire-resistant clearance members secured to said opposite sides ofsaid spline member, and

(k) said clearance members being of less lateral extent than said splinemember, thereby clearing said ends of said fasteners.

2. In the building structure recited in claim 1:

(a) a fixed Wall,

(b) one panel of said modular panels having a terminal end disposed inangular relation to a fixed wall,

(c) said terminal end including a pair of terminal Wallboards disposedin spaced substantially parallel relation and having terminal edges anda channelshaped terminal spacer member interposed between said terminalwallboards along said terminal edges thereof,

.and

(d) said terminal wallboards and said terminal spacer member defining aterminal air space,

(c) said terminal spacer member including a web bridging said terminalair space between said terminal wallboards and a pair of substantiallyparallel flanges extending toward, but terminating short of, saidterminal edges of said terminal wallboards,

(f) fasteners penetrating said terminal wallboards and said flanges ofsaid terminal spacer member,

(1) each fastener having an end extending inwardly of said terminalspacer member,

(g) said terminal edges of said terminal wallboards being positioned inabutting relationship with said fixed wall and forming terminal jointsbetween said terminal wallboards and said fixed wall,

(h) said terminal spacer member contiguous to said joints forming acavity with said fixed wall,

(i) said flanges of said terminal spacer member being spaced apart anddefining a terminal gap on the side of said terminal cavity opposite tosaid fixed wall,

(j) a fire-resistant terminal spline member disposed in and bridgingsaid terminal cavity,

(k) the lateral side of said terminal spline member adjacent said web ofsaid terminal spacer member being seated in said terminal gap andoverlying said flanges of said terminal spacer member,

(1) a fire-resistant terminal clearance member secured to said terminalspline member, and

(in) said terminal clearance member being of less lateral extent thatsaid terminal spline member, thereby clearing said ends of saidfasteners.

3. In the building structures recited in claim 1:

(a) an internal support member disposed in said air space between saidspacer members,

(b) said internal support member having:

(1) a channel-shaped internal spacer member interposed between saidwallboards,

(2) said internal spacer members including a Web bridging said air spacebetween said wallboards and a pair of substantially parallel flangesextending toward one of said spacer members,

(3) said flanges of said internal spacer member being spaced apart anddefining a heat sink gap,

(4) a heat sink member in said heat sink gap, and

(5) fasteners penetrating said wallboards and said flanges of saidinternal spacer member and extending into said heat sink member.

4. In the building structure recited in claim 3 said heat sink membercontains a material having a latent heat of vaporization, said material36, 36 being operable to prevent a temperature rise in said fastenersduring vaporization of said material.

5. In the building structure recited in claim 4, said material ismechanically bonded to said heat sink member.

6. In the building structure recited in claim 4, said material ischemically bonded to said heat sink member.

7. In the building structure recited in claim 1:

(a) an internal support member disposed in said air space between saidspacer member,

(b) said internal support member having:

(1) a hollow internal spacer member interposed between said wallboards,

(2) said internal spacer member including a Web bridging said air spacebetween said wallboards and a pair of substantially parallel flanges,

(3) said internal spacer member being provided with a heat sink gap,

(4) a heat sink member in said heat sink gap, and

(5) fasteners penetrating said wallboards and said flanges of saidinternal spacer member and extending into said heat sink member,

(6) said heat sink member 34 having therein a material operable toprevent a temperature rise in said fasteners during vaporization of saidmaterial.

8. In the building structures recited in claim 1:

(a) an internal support member disposed in said air space between saidspacer members,

(b) said internal support member having:

(1) a channel-shaped internal spacer member interposed between saidwallboards,

(2) said internal spacer member including a web bridging said air spacebetween said wallboards and a pair of substantially parallel flangesextending toward one of said spacer members,

(3) said flanges of said internal spacer member being spaced apart anddefining a heat sink gap,

(4) a heat sink member in said heat sink gap, and

(5) adhesive fasteners connecting said flanges of said internal spacermember to said wallboards.

9. In the building structure recited in claim 1:

(a) a second partition Wall disposed in substantially parallel relationto said partition Wall and defining with said partition wall an internalair space,

(b) said second partition wall comprising a plurality of aligned modularsecond panels,

(1) each second panel including a pair of second wallboards disposed inspaced substantially parallel relation and having contiguous edges ofsaid second wallboards of said aligned second panels positioned inabutting relationship and forming second joints between said alignedsecond wallboards, and a pair of opposed channelshaped second spacermembers interposed between said second wallboards adjacent said secondjoints,

(c) said second wallboards and said second spacer members defining asecond air space,

(d) each second spacer member including a second web bridging saidsecond air space between said second wallboards and a pair ofsubstantially parallel second flanges extending toward, but terminatingshort of, said second joints of said second wallboards, and

(e) means for connecting said second flanges to said second wallboards,

(f) said second joints being displaced from said joints of saidpartition wall to provide a tortuous fire path through said secondpartition wall and said partition wall.

10. In the building structure recited in claim 1:

(a) a second partition wall disposed in substantially parallel relationto said partition wall and defining with said partition wall an internalair space,.

(b) said second partition wall comprising a plurality of aligned modularsecond panels,

(1) each second panel including a pair of second wallboards disposed inspaced substantially parallel relation and having contiguous edges ofsaid second wallboards of said aligned second panels positioned inabuttin: relationship and forming second joints between said alignedsecond wallboards, and a pair of opposed channelshaped second spacermembers interposed between said second wallboards adjacent said secondjoints,

(c) said second wallboards and said second spacer members defining asecond air space,

(d) each second spacer member including a second web bridging saidsecond air space between said second wallboards and a pair ofsubstantially parallel second flanges extending toward, but terminatingshort of, said second joints of said second wallboards,

(6) means for connecting said second flanges to said second wallboards,V

(f) a filler wallboard member in said internal air space and spaced fromsaid partition wall and said second partition wall, and

(g) spacing fasteners each having a head protruding a predetermineddistance from said filler wallboard member, extending through saidfiller wallboard member and one wallboard of the adjacent wallboards ofsaid partition wall and said second partition wall, and being operableto create projecting bulges in the adjacent surfaces of said fillerwallboard member and said one wallboard to space said filler wallboardmembers from said one wallboard,

(h) said other wallboard of the adjacent wallboards of said partitionwall and said second partition wall being positioned against saidprotruding heads of said spacing fasteners.

11. In the building structure recited in claim 10:

(a) adhesive means for securing said filler wallboard member to saidother wallboard.

12. In the building structure recited in claim 10:

(a) spacing fasteners which are wallboard screws.

13. In the building structure recited in claim 10:

(a) spacing fasteners which are of the toggle type.

14. In the building structure recited in claim 10:

(a) spacing fasteners which are of the anchor type.

References Cited UNITED STATES PATENTS 275,000 1883 Waters 52-481533,856 1895 Baker 52-481 593,804 1897 Hintze 52-481 965,595 7/1910Nicholson 52-481 1,475,409 11/1923 Riddle 52-241 1,603,895 10/1926Berger 52-241 2,172,358 9/1939 Burson 52-243 3,050,134 8/1962 Multin169-5 3,174,387 3/1965 Fischer -71 3,298,725 1/1967 Boteler 85-843,305,981 2/1967 Biggs 52-317 FOREIGN PATENTS 252,285 1964 Australia.685,565 1964 Canada.

HENRY C. SUTHERLAND, Primary Examiner US. Cl. X.R.

